WO2021014512A1 - Power converter - Google Patents

Power converter Download PDF

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Publication number
WO2021014512A1
WO2021014512A1 PCT/JP2019/028536 JP2019028536W WO2021014512A1 WO 2021014512 A1 WO2021014512 A1 WO 2021014512A1 JP 2019028536 W JP2019028536 W JP 2019028536W WO 2021014512 A1 WO2021014512 A1 WO 2021014512A1
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WO
WIPO (PCT)
Prior art keywords
flat plate
bus bar
terminal
power
capacitor
Prior art date
Application number
PCT/JP2019/028536
Other languages
French (fr)
Japanese (ja)
Inventor
皓一 古川
泰輔 藁科
遥 飯島
Original Assignee
株式会社デンソー
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by 株式会社デンソー filed Critical 株式会社デンソー
Priority to JP2021534871A priority Critical patent/JP7092268B2/en
Priority to PCT/JP2019/028536 priority patent/WO2021014512A1/en
Publication of WO2021014512A1 publication Critical patent/WO2021014512A1/en

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    • H—ELECTRICITY
    • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02M—APPARATUS FOR CONVERSION BETWEEN AC AND AC, BETWEEN AC AND DC, OR BETWEEN DC AND DC, AND FOR USE WITH MAINS OR SIMILAR POWER SUPPLY SYSTEMS; CONVERSION OF DC OR AC INPUT POWER INTO SURGE OUTPUT POWER; CONTROL OR REGULATION THEREOF
    • H02M7/00—Conversion of ac power input into dc power output; Conversion of dc power input into ac power output
    • H02M7/42—Conversion of dc power input into ac power output without possibility of reversal
    • H02M7/44—Conversion of dc power input into ac power output without possibility of reversal by static converters
    • H02M7/48—Conversion of dc power input into ac power output without possibility of reversal by static converters using discharge tubes with control electrode or semiconductor devices with control electrode

Definitions

  • the technology disclosed in this specification relates to a power converter.
  • the present invention relates to a power converter in which a laminated unit in which a plurality of power modules are laminated and a capacitor are connected by a bus bar.
  • Each power module contains one or more switching elements for power conversion.
  • the conductor that electrically connects the terminals of the power module and the capacitor is sometimes called a bus bar.
  • the power module and the capacitor are connected by two buses.
  • the power converter disclosed in Documents 1 and 2 has the following structure.
  • Each power module included in the stacking unit contains a switching element for power conversion.
  • a first terminal and a second terminal conducting with the switching element extend from the side surface of each power module.
  • the capacitors are located next to the stacking unit.
  • the first terminal of the plurality of power modules and one electrode of the capacitor are connected by the first bus bar.
  • the second terminal of the plurality of power modules and the other electrode of the capacitor are connected by a second bus bar.
  • the first bus bar is provided with a first flat plate, a plurality of first holes, and a plurality of first branch portions.
  • the first flat plate extends from the capacitor along the side surface of the power module.
  • the plurality of first holes are provided in the first flat plate.
  • the first terminal of the corresponding power module passes through each of the plurality of first holes.
  • Each first branch extends from the edge of the corresponding first hole along the first terminal and is connected to the first terminal.
  • the second bus bar has the same structure as the first bus bar, and includes a second flat plate, a plurality of second holes, and a plurality of second branches. A second terminal passes through each of the second holes, and each second terminal is connected to each second branch.
  • the first bus bar and the second bus bar are a positive electrode bus bar connected to the positive electrode of the capacitor and a negative electrode bus bar connected to the negative electrode of the capacitor.
  • the stacking direction of a plurality of power modules will be referred to as a first direction.
  • the first flat plate and the second flat plate are provided with ribs at both ends in the first direction.
  • a direction orthogonal to the first direction and parallel to the first flat plate will be referred to as a second direction.
  • the ribs do not significantly contribute to the suppression of deformation of the first flat plate (second flat plate) when viewed from the second direction.
  • This specification describes the deformation (particularly when the second plate) of the first plate (second plate) of the first bus bar (second bus bar) connecting the capacitors to the plurality of first terminals (second terminals) of the laminated unit (especially when the second plate is bitten).
  • the power converter disclosed in the present specification includes a laminated unit in which a plurality of power modules are laminated, a capacitor arranged next to the laminated unit, a first bus bar, and a second bus bar.
  • Each power module contains a switching element for power conversion.
  • the first terminal and the second terminal conducting with the switching element extend from the side surface of the power module.
  • the first terminals of the plurality of power modules are arranged in a row along the stacking direction (first direction) of the power modules, and the plurality of second terminals are arranged in a row in parallel with the row of the first terminals.
  • the first bus bar is connected to the first terminals of a plurality of power modules and is also connected to one electrode of the capacitor.
  • the first bus bar includes a first flat plate extending from the capacitor along the side surface of the power module (the side surface where the first terminal and the second terminal are provided).
  • the first flat plate is provided with a plurality of first holes and a plurality of first branch portions.
  • the first terminal passes through each of the plurality of first holes.
  • Each first branch extends from the edge of each first hole and is connected to each first terminal.
  • the second bus bar is connected to the second terminal of a plurality of power modules and is connected to the other electrode of the capacitor.
  • the second bus bar includes a second plate extending from the capacitor in parallel with the first plate.
  • the second flat plate is provided with a plurality of second holes and a plurality of second branch portions.
  • the second terminal passes through each of the plurality of second holes.
  • Each second branch extends from the edge of each second hole and is connected to each second terminal.
  • the first rib is provided on the edge far from the capacitor of the first flat plate. Due to this first rib, the deformation of the first flat plate when viewed from the second direction is suppressed.
  • a second rib may be provided on the edge far from the capacitor of the second flat plate. The second rib suppresses the deformation of the second flat plate when viewed from the second direction.
  • the first rib and the second rib extend from the respective flat plates along the third direction.
  • the third direction is a direction orthogonal to both the first direction and the second direction.
  • the first rib and the second rib extend in a direction separated from each other in the third direction.
  • the first rib and the second rib extending in the direction away from each other do not interfere with each other.
  • FIG. 1 It is a block diagram of the electric power system of the electric vehicle including the electric power converter of an Example. It is a perspective view of the assembly of a laminated unit, a bus bar and a capacitor unit. It is an exploded perspective view of an assembly. It is a perspective view of the assembly of the power converter of a modification. It is an enlarged view of the vicinity of the notch in FIG.
  • FIG. 1 shows a block diagram of an electric power system of an electric vehicle 100 including a power converter 2.
  • the electric vehicle 100 includes two traveling motors 83a and 83b. Therefore, the power converter 2 includes two sets of inverter circuits 13a and 13b. The outputs of the two motors 83a and 83b are combined / distributed by the gearbox 85 and transmitted to the axle 86 (that is, the drive wheels).
  • the power converter 2 is connected to the battery 81 via the system main relay 82.
  • the power converter 2 includes a voltage converter circuit 12 that boosts the voltage of the battery 81, and two sets of inverter circuits 13a and 13b that convert the boosted DC power into alternating current.
  • the voltage converter circuit 12 is a bidirectional DC-DC converter capable of performing both step-up operation and step-down operation.
  • the voltage converter circuit 12 boosts the voltage applied to the terminal on the battery side and outputs it to the terminal on the inverter side.
  • the voltage converter circuit 12 steps down the voltage applied to the terminal on the inverter side and outputs it to the terminal on the battery side.
  • the terminal on the battery side low voltage side
  • the terminal on the inverter side high voltage side
  • the positive electrode and the negative electrode of the input end 18 are referred to as an input positive electrode end 18a and an input negative electrode end 18b, respectively.
  • the positive electrode and the negative electrode of the output end 19 are referred to as an output positive electrode end 19a and an output negative electrode end 19b, respectively.
  • the notations "input end 18" and "output end 19" are for convenience of explanation. As described above, since the voltage converter circuit 12 is a bidirectional DC-DC converter, the output end Power may flow from 19 to the input end 18.
  • the voltage converter circuit 12 is composed of a series circuit of two switching elements 9a and 9b, a reactor 7, a filter capacitor 5, and a diode connected in antiparallel to each switching element.
  • One end of the reactor 7 is connected to the input positive electrode end 18a, and the other end is connected to the midpoint of the series circuit.
  • the filter capacitor 5 is connected between the input positive electrode end 18a and the input negative electrode end 18b.
  • the input negative electrode end 18b is directly connected to the output negative electrode end 19b.
  • the switching element 9b is mainly involved in the step-up operation, and the switching element 9a is mainly involved in the step-down operation. Since the voltage converter circuit 12 of FIG. 1 is well known, detailed description thereof will be omitted.
  • Reference numerals 25a and 25b indicate terminals extending from the power module 8a.
  • Reference numeral 25a indicates a terminal (positive electrode terminal 25a) conducting with the high potential side of the series circuit of the switching elements 9a and 9b.
  • Reference numeral 25b represents a terminal (negative electrode terminal 25b) conducting with the low potential side of the series circuit of the switching elements 9a and 9b.
  • the notation of positive electrode terminal 25a and negative electrode terminal 25b is also used in other power modules.
  • the terminal connected to the midpoint of the series connection of the two switching elements is referred to as a midpoint terminal.
  • the inverter circuit 13a has a configuration in which three sets of series circuits of two switching elements are connected in parallel.
  • the switching elements 9c and 9d, the switching elements 9e and 9f, and the switching elements 9g and 9h form a series circuit, respectively. Diodes are connected in anti-parallel to each switching element.
  • the high potential side terminal (positive electrode terminal 25a) of the three sets of series circuits is connected to the output positive electrode end 19a of the voltage converter circuit 12, and the low potential side terminal (negative electrode terminal 25b) of the three sets of series circuits is voltage. It is connected to the output negative electrode end 19b of the converter circuit 12.
  • Three-phase alternating current (U phase, V phase, W phase) is output from the midpoint terminal of the three sets of series circuits.
  • Each of the three sets of series circuits corresponds to the power modules 8b, 8c, and 8d described later.
  • the inverter circuit 13b Since the configuration of the inverter circuit 13b is the same as that of the inverter circuit 13a, the specific circuit is not shown in FIG. Similar to the inverter circuit 13a, the inverter circuit 13b also has a configuration in which three sets of series circuits of two switching elements are connected in parallel. The terminal on the high potential side of the three sets of series circuits is connected to the output positive end 19a of the voltage converter circuit 12, and the terminal on the low potential side of the three sets of series circuits is connected to the output negative end 19b of the voltage converter circuit 12. Has been done.
  • the hardware corresponding to each series circuit is referred to as a power module 8e, 8f, 8g.
  • a smoothing capacitor 6 is connected in parallel to the input ends of the inverter circuits 13a and 13b. In other words, the smoothing capacitor 6 is connected in parallel to the output terminal 19 of the voltage converter circuit 12. The smoothing capacitor 6 eliminates the pulsation of the output current of the voltage converter circuit 12.
  • the switching elements 9a-9h are transistors, typically IGBTs (Insulated Gate Bipolar Transistors), but may be other transistors, for example, MOSFETs (Metal Oxide Semiconductor Field Effect Transistors). Further, the switching element referred to here is used for power conversion, and is sometimes called a power semiconductor element.
  • each of the broken lines 8a-8g corresponds to the power module.
  • the power converter 2 includes seven sets of a series circuit of two switching elements. As hardware, two switching elements constituting a series circuit and a diode connected in antiparallel to each switching element are housed in one package (main body of a power module). In the following, when any one of the power modules 8a to 8g is shown without distinction, it is referred to as the power module 8.
  • the high potential side terminal (positive electrode terminal 25a) of the seven power modules (7 sets of series circuits) is connected to the positive electrode of the smoothing capacitor 6, and the low potential side terminal (negative electrode terminal 25b) is the negative of the smoothing capacitor 6.
  • the conductive path in the broken line indicated by reference numeral 30 corresponds to a bus bar (positive electrode bus bar) that connects the positive electrode terminals 25a of the plurality of power modules 8 and the positive electrodes of the smoothing capacitor 6 to each other.
  • the conductive path in the broken line indicated by reference numeral 40 corresponds to a bus bar (negative electrode bus bar) that connects the plurality of negative electrode terminals 25b and the negative electrodes of the smoothing capacitor 6 to each other.
  • FIG. 2 shows a perspective view of the hardware of the power converter 2.
  • the housing of the power converter 2 and some parts are not shown.
  • the plurality of power modules 8 (8a-8g) together with the plurality of coolers 22 constitute a stacking unit 20. Since the power modules 8a-8g all have the same shape, in FIGS. 2 and 3, only the leftmost power module is designated by reference numeral 8, and the other power modules are designated by reference numerals. Further, in FIGS. 2 and 3, the reference numerals 22 are attached only to the two leftmost coolers, and the reference numerals are omitted for the other coolers. FIG. 3 will be described later.
  • FIG. 2 is a perspective view of the power converter 2, but only the assembly of the laminated unit 20, the positive electrode bus bar 30, the negative electrode bus bar 40, and the capacitor unit 60 is drawn, and the other parts are not shown.
  • the stacking unit 20 a plurality of power modules 8 are laminated.
  • the stacking unit 20 is a device in which a plurality of card-type coolers 22 are arranged in parallel, and a card-type power module 8 is sandwiched between adjacent coolers 22.
  • the card-type power module 8 has its wide surface facing the cooler 22.
  • the X direction of the coordinate system in the figure corresponds to the stacking direction of the plurality of power modules 8. In the following figures, the X direction also indicates the stacking direction.
  • Three terminals extend from one side surface 80a of each power module 8.
  • reference numerals 25a, 25b, and 25c are attached only to the terminals of the power module 8 located at the left end of the stacking unit 20, and the reference numerals indicating the terminals are omitted from the remaining power modules 8.
  • the positive electrode terminal 25a and the negative electrode terminal 25b are a terminal on the high potential side and a terminal on the low potential side of the series circuit housed in the power module 8.
  • the midpoint terminal 25c is a terminal conducting with the midpoint of the series circuit. In other words, all three terminals 25a-25c are conducting with the switching element inside the power module 8.
  • the three terminals 25a-25c extend in the positive direction of the Z axis in the drawing from one side surface 80a intersecting the wide surface of the power module 8.
  • a plurality of control terminals extend in the negative direction of the Z axis in the drawing from the side surface opposite to one side surface 80a.
  • the control terminals are a gate terminal conducting with the gate electrode of the switching element built in the power module 8, a signal terminal conducting with the temperature sensor and the current sensor built in the power module 8, and the like. ..
  • the rightmost cooler 22 in the figure is provided with a refrigerant supply port 28 and a refrigerant discharge port 29.
  • the adjacent coolers 22 are connected by two connecting pipes.
  • One connecting pipe is positioned so as to overlap the refrigerant supply port 28 when viewed from the stacking direction.
  • the other connecting pipe is positioned so as to overlap the refrigerant discharge port 29 when viewed from the stacking direction.
  • a refrigerant circulation device (not shown) is connected to the refrigerant supply port 28 and the refrigerant discharge port 29.
  • the refrigerant supplied from the refrigerant supply port 28 is distributed to all the coolers 22 through one connecting pipe.
  • the refrigerant absorbs heat from the adjacent power module 8 while passing through the cooler 22.
  • the heat-absorbed refrigerant is discharged from the stacking unit 20 through the other connecting pipe and the refrigerant discharge port 29. Since each power module 8 is cooled from both sides thereof, the laminated unit 20 has high cooling performance.
  • the three terminals 25a-25c of each power module 8 are all flat plates.
  • the positive electrode terminals 25a of the plurality of power modules 8 are arranged in a row in the X direction (stacking direction) so as to face the flat surface of the positive electrode terminals 25a of the adjacent power modules 8.
  • the negative electrode terminals 25b of the plurality of power modules 8 are also arranged in a row in the X direction (stacking direction) so as to face the flat surface of the negative electrode terminals 25b of the adjacent power modules 8.
  • the rows of the positive electrode terminals 25a, the rows of the negative electrode terminals 25b, and the rows of the midpoint terminals 25c of the plurality of power modules 8 are parallel.
  • the capacitor unit 60 is arranged next to the laminated unit 20.
  • the capacitor unit 60 is long along the stacking direction (X direction in the figure) of the power module 8.
  • the capacitor unit 60 is aligned with the stacking unit 20 in a direction (Y direction) intersecting the stacking direction.
  • Two capacitor elements 61 (described later) are housed in the case of the capacitor unit 60.
  • the positive electrode bus bar 30 connects the positive electrode terminals 25a of the plurality of power modules 8 to the capacitor elements in the capacitor unit 60
  • the negative electrode bus bar 40 connects the negative electrode terminals 25b of the plurality of power modules 8 to the capacitors.
  • the capacitor element in the unit 60 is connected.
  • FIG. 3 shows an exploded perspective view of the assembly of the positive electrode bus bar 30, the negative electrode bus bar 40, the laminated unit 20, and the capacitor element 61 (capacitor unit 60).
  • the capacitor unit 60 of FIG. 2 accommodates two capacitor elements 61.
  • the case of the capacitor unit 60 is omitted, and the internal capacitor element 61 is drawn. Although details are omitted, the periphery of the capacitor element 61 in the case of the capacitor unit 60 is filled with a filler.
  • the capacitor element 61 corresponds to the smoothing capacitor 6 in FIG.
  • the positive electrode 25a of the plurality of power modules 8 and the positive electrode 61a of the capacitor element 61 are connected by the positive electrode bus bar 30, and the plurality of negative electrode terminals 25b and the negative electrode 61b of the capacitor element 61 are connected by the negative electrode bus bar 40.
  • the positive electrode bus bar 30 includes a plate-shaped electrode portion 39 and a flat plate 31.
  • the flat plate 31 is provided with a plurality of positive electrode terminal holes 32 and a plurality of branch portions 33.
  • the electrode portion 39 is connected to the positive electrode 61a of the capacitor element 61.
  • the plurality of positive electrode terminal holes 32 are arranged in a row along the X direction.
  • a branch portion 33 extends in the Z direction from the edge of each positive electrode terminal hole 32.
  • the positive electrode terminal 25a of the power module 8 corresponding to each positive electrode terminal hole 32 passes through, and the positive electrode terminal 25a and the branch portion 33 are joined by welding.
  • the negative electrode bus bar 40 includes a plate-shaped electrode portion 49 and a flat plate 41.
  • the flat plate 41 is provided with a plurality of negative electrode terminal holes 42 and a plurality of branch portions 43.
  • the electrode portion 49 is connected to the negative electrode 61b of the capacitor element 61.
  • the plurality of negative electrode terminal holes 42 are arranged in a row along the X direction.
  • a branch portion 43 extends in the Z direction from the edge of each negative electrode terminal hole 42.
  • the negative electrode terminal 25b of the power module 8 corresponding to each negative electrode terminal hole 42 passes through, and the negative electrode terminal 25b and the branch portion 43 are joined.
  • the negative electrode bus bar 40 is located on the opposite side of the laminated unit 20 of the positive electrode bus bar 30.
  • the negative electrode bus bar 40 is provided with a plurality of positive electrode terminal holes 45.
  • the positive electrode terminal 25a of the power module 8 and the branch portion 33 of the positive electrode bus bar 30 pass through each of the positive electrode terminal holes 45.
  • the flat plate 31 of the positive electrode bus bar 30 and the flat plate 41 of the negative electrode bus bar 40 are arranged in parallel with the insulating plate 50 (described later) interposed therebetween and are close to each other.
  • an eddy current is generated in the other bus bar by the magnetic field of one bus bar.
  • the generation of eddy currents weakens the magnetic field of one bus bar.
  • the weakening of the magnetic field means that the inductance becomes smaller.
  • the insulating plate 50 is sandwiched between the positive electrode bus bar 30 and the negative electrode bus bar 40.
  • the insulating plate 50 insulates between the positive electrode bus bar 30 and the negative electrode bus bar 40.
  • the insulating plate 50 is provided with a plurality of tubular portions 53. Ribs 57 extending in the Y direction are provided on both sides of the insulating plate 50 in the stacking direction (X direction). As shown in FIG. 2, the rib 57 is sandwiched between the reinforcing rib 37 of the positive electrode bus bar 30 and the reinforcing rib 47 of the negative electrode bus bar 40 to insulate both of them. Reinforcing ribs 37 and 47 will be described later.
  • the tubular portion 53 of the insulating plate 50 passes through the positive electrode terminal hole 45 of the negative electrode bus bar 40.
  • the branch portion 33 of the positive electrode bus bar 30 and the positive electrode terminal 25a of the power module 8 pass through the inside of the tubular portion 53.
  • the tubular portion 53 reliably insulates the positive electrode terminal 25a and the branch portion 33 from the negative electrode bus bar 40.
  • Both ends of the flat plate 31 of the positive electrode bus bar 30 in the stacking direction (X direction) are bent at right angles.
  • the portion bent at a right angle is referred to as a reinforcing rib 37.
  • Both ends of the flat plate 41 of the negative electrode bus bar 40 in the stacking direction (X direction) are also bent at right angles.
  • the portion bent at a right angle is referred to as a reinforcing rib 47.
  • the capacitor element 61 is housed in the case and is embedded in the filler in the case. Therefore, a part of the positive electrode bus bar 30 and a part of the negative electrode bus bar 40 are also embedded in the filler in the case of the capacitor unit 60. Naturally, the electrode portions 39 and 49 will be embedded in the filler.
  • a part 31a of the flat plate 31 of the positive electrode bus bar 30 is also embedded in the filler, and a part 41a of the flat plate 41 of the negative electrode bus bar 40 is also embedded in the filler.
  • the portion indicated by reference numerals 31b and 41b is an exposed portion exposed from the capacitor unit 60 in the flat plates 31 and 41.
  • a part 37a of the reinforcing rib 37 and a part 47a of the reinforcing rib 47 are also embedded in the filler.
  • Reinforcing ribs 38 are also provided on the edge of the positive electrode bus bar 30 (flat plate 31) farthest from the condenser element 61.
  • the reinforcing rib 38 is provided on the edge of the flat plate 31 extending in the X direction on the side farther from the capacitor element 61.
  • Reinforcing ribs 48 are also provided on the edge of the negative electrode bus bar 40 (flat plate 41) on the side far from the capacitor element 61.
  • the reinforcing rib 48 is provided on the edge of the flat plate 41 extending in the X direction on the side farther from the capacitor element 61.
  • the reinforcing rib 38 extends from the flat plate 31 in the -Z direction.
  • the reinforcing rib 48 extends from the flat plate 41 in the + Z direction. That is, the reinforcing rib 38 and the reinforcing rib 48 extend in a direction away from each other. Therefore, even if the positive electrode bus bar 30 and the negative electrode bus bar 40 overlap, the reinforcing rib 38 and the reinforcing rib 48 do not interfere with each other.
  • the reinforcing rib 37 described above increases the rigidity of the positive electrode bus bar 30 (flat plate 31) against bending when viewed from the X direction. In other words, the reinforcing rib 37 suppresses the deformation of the positive electrode bus bar 30 (flat plate 31) around the axis extending in the X direction.
  • the reinforcing rib 38 increases the rigidity of the positive electrode bus bar 30 (flat plate 31) against bending when viewed from the Y direction. In other words, the reinforcing rib 38 suppresses the deformation of the positive electrode bus bar 30 (flat plate 31) around the axis extending in the Y direction.
  • the reinforcing rib 47 increases the rigidity of the negative electrode bus bar 40 (flat plate 41) against bending when viewed from the X direction. In other words, the reinforcing rib 47 suppresses deformation of the negative electrode bus bar 40 (flat plate 41) around the axis extending in the X direction.
  • the reinforcing rib 48 increases the rigidity of the negative electrode bus bar 40 (flat plate 41) against bending when viewed from the Y direction. In other words, the reinforcing rib 48 suppresses deformation of the negative electrode bus bar 40 (flat plate 41) around the axis extending in the Y direction.
  • the branch portion 33 of the positive electrode bus bar 30 is joined to the positive electrode terminal 25a of the power module 8.
  • the branch portion 33 and the positive electrode terminal 25a are gripped by the chuck.
  • the flat plate 31 of the positive electrode bus bar 30 may be deformed by the force received from the chuck.
  • the reinforcing rib 38 suppresses deformation of the flat plate 31 due to the force of the chuck.
  • the same applies to the negative electrode bus bar 40, and the reinforcing rib 48 suppresses the deformation of the flat plate 41 due to the force of the chuck (the force sandwiching the branch portion 43 and the negative electrode terminal 25b).
  • Reinforcing ribs 37 and 38 are made by bending one flat plate (flat plate 31).
  • the reinforcing ribs 47 and 48 are made by bending one flat plate (flat plate 41).
  • FIG. 4 shows a perspective view of a modified power converter 2a.
  • FIG. 4 corresponds to FIG.
  • each of the plurality of power modules 8 is given a unique reference numeral (8a-8g).
  • the reinforcing ribs 138 and 148 of the power converter 2a of the modified example are different from the reinforcing ribs 38 and 48 of the power converter 2 of the embodiment.
  • the structure of the power converter 2a is the same as that of the power converter 2 except for the reinforcing ribs 138 and 148.
  • Reinforcing rib 148 has two notches 149a and 149b.
  • FIG. 5 shows an enlarged view of the vicinity of the notch 149a.
  • the notches 149a and 149b reach the negative electrode terminal hole 42.
  • the reinforcing rib 148 suppresses the deformation of the flat plate 41 when viewed from the Y direction.
  • the reinforcing rib 148 by providing the reinforcing rib 148, the rigidity of the flat plate 41 is increased, and stress may be locally concentrated when a force is applied.
  • the stress concentration when the flat plate 41 receives a force is relaxed.
  • the notch 149a is provided between the power module 8a and the power module 8b. More specifically, the notch 149a is provided between the midpoint terminal 25c of the power module 8a and the midpoint terminal 25c of the power module 8b. As described with reference to FIG. 1, the power module 8a is used in the voltage converter circuit 12, and the power module 8b is used in the inverter circuit 13a. That is, the notch 149a is provided between the two power modules 8a and 8b used in different conversion circuits.
  • the switching elements of the power modules 8a and 8b operate at timings independent of each other, and switching noise interferes with each other.
  • the notch 149a reduces noise interference from switching elements that operate at mutually independent timings.
  • the notch 149b is provided between the power module 8d and the power module 8e. More specifically, the notch 149b is provided between the midpoint terminal 25c of the power module 8d and the midpoint terminal 25c of the power module 8e.
  • the power module 8d is used in the inverter circuit 13a
  • the power module 8e is used in the inverter circuit 13b.
  • the switching elements of the power modules 8d and 8e operate at timings independent of each other, and switching noise interferes with each other.
  • the notch 149b also reduces noise interference from switching elements that operate at mutually independent timings.
  • a similar notch is provided in the reinforcing rib 138 of the positive electrode bus bar 30.
  • the notch provided in the reinforcing rib 138 has the same effect as the notch 149a and 149b of the reinforcing rib 148.
  • the negative electrode bus bar 40 of the embodiment corresponds to an example of the first bus bar.
  • Each of the flat plate 41, the negative electrode terminal hole 42, and the branch portion 43 of the negative electrode bus bar 40 corresponds to an example of the first flat plate, the first hole, and the first branch portion.
  • the positive electrode bus bar 30 of the embodiment corresponds to an example of the second bus bar.
  • Each of the flat plate 31, the positive electrode terminal hole 32, and the branch portion 33 of the positive electrode bus bar 30 corresponds to an example of the second flat plate, the second hole, and the second branch portion.
  • the reinforcing rib 48 corresponds to an example of the first rib.
  • the reinforcing rib 38 corresponds to an example of the second rib.
  • the X direction of the coordinate system in the figure corresponds to the first direction
  • the Y direction corresponds to the second direction.

Abstract

The present invention suppresses deformation of a positive-electrode busbar and a negative-electrode busbar. A power converter 2 comprises a first busbar 30 that connects a terminal 25a of a power module 8 to a capacitor 60. The first busbar 30 comprises: a first flat plate 31; a plurality of first holes 32 provided to the first flat plate 31; and first branch parts 33 extending from an edge of each of the first holes 32. A reinforcing rib 38 is provided on the edge of the first flat plate 31 which is far from the capacitor 60. The reinforcing rib 38 suppresses deformation of the first flat plate 31 when viewed from the Y direction.

Description

電力変換器Power converter
　本明細書が開示する技術は、電力変換器に関する。特に、複数のパワーモジュールが積層されている積層ユニットとコンデンサがバスバで接続されている電力変換器に関する。 The technology disclosed in this specification relates to a power converter. In particular, the present invention relates to a power converter in which a laminated unit in which a plurality of power modules are laminated and a capacitor are connected by a bus bar.
　上記した電力変換器が例えば特開２０１８－０４２４２４号公報（文献１）、特開２０１８－０４２３０９号公報（文献２）、特開２０１８－０２６８８５号公報（文献３）に開示されている。各パワーモジュールは、１個あるいは複数個の電力変換用のスイッチング素子を収容している。パワーモジュールが有する端子とコンデンサを電気的に接続する導体はバスバと呼ばれることがある。パワーモジュールとコンデンサは、２個のバスバで接続される。 The above-mentioned power converter is disclosed in, for example, JP-A-2018-0422424 (Reference 1), JP-A-2018-042309 (Reference 2), and JP-A-2018-026885 (Reference 3). Each power module contains one or more switching elements for power conversion. The conductor that electrically connects the terminals of the power module and the capacitor is sometimes called a bus bar. The power module and the capacitor are connected by two buses.
　文献１と文献２に開示された電力変換器は、次の構造を有している。積層ユニットに含まれている各パワーモジュールには電力変換用のスイッチング素子が収容されている。各パワーモジュールの側面から、スイッチング素子と導通している第１端子と第２端子が延びている。コンデンサは積層ユニットの隣りに配置されている。複数のパワーモジュールの第１端子とコンデンサの一方の電極は第１バスバで接続されている。複数のパワーモジュールの第２端子とコンデンサの他方の電極は第２バスバで接続されている。 The power converter disclosed in Documents 1 and 2 has the following structure. Each power module included in the stacking unit contains a switching element for power conversion. A first terminal and a second terminal conducting with the switching element extend from the side surface of each power module. The capacitors are located next to the stacking unit. The first terminal of the plurality of power modules and one electrode of the capacitor are connected by the first bus bar. The second terminal of the plurality of power modules and the other electrode of the capacitor are connected by a second bus bar.
　第１バスバは、第１平板と、複数の第１孔と、複数の第１枝部を備えている。第１平板は、コンデンサからパワーモジュールの側面に沿って延びている。複数の第１孔は、第１平板に設けられている。複数の第１孔のそれぞれに、対応するパワーモジュールの第１端子が通過している。それぞれの第１枝部は、対応する第１孔の縁から第１端子に沿って延びており、第１端子と接続されている。第２バスバは、第１バスバと同様の構造を有しており、第２平板と、複数の第２孔と、複数の第２枝部を備えている。それぞれの第２孔に第２端子が通過しており、それぞれの第２枝部にそれぞれの第２端子が接続されている。第１バスバと第２バスバは、具体的には、コンデンサの正極と接続される正極バスバと、コンデンサの負極と接続される負極バスバである。 The first bus bar is provided with a first flat plate, a plurality of first holes, and a plurality of first branch portions. The first flat plate extends from the capacitor along the side surface of the power module. The plurality of first holes are provided in the first flat plate. The first terminal of the corresponding power module passes through each of the plurality of first holes. Each first branch extends from the edge of the corresponding first hole along the first terminal and is connected to the first terminal. The second bus bar has the same structure as the first bus bar, and includes a second flat plate, a plurality of second holes, and a plurality of second branches. A second terminal passes through each of the second holes, and each second terminal is connected to each second branch. Specifically, the first bus bar and the second bus bar are a positive electrode bus bar connected to the positive electrode of the capacitor and a negative electrode bus bar connected to the negative electrode of the capacitor.
　以下では、説明の便宜上、複数のパワーモジュールの積層方向を第１方向と称する。文献１に開示されている電力変換器では、第１平板と第２平板は、第１方向の両端にリブを備えている。リブを備えることで第１平板と第２平板の剛性が向上し、第１平板と第２平板の変形が抑えられる。 In the following, for convenience of explanation, the stacking direction of a plurality of power modules will be referred to as a first direction. In the power converter disclosed in Document 1, the first flat plate and the second flat plate are provided with ribs at both ends in the first direction. By providing the ribs, the rigidity of the first flat plate and the second flat plate is improved, and the deformation of the first flat plate and the second flat plate is suppressed.
　以下では、説明の便宜上、第１方向に直交するとともに第１平板に対して平行な方向を第２方向と称する。上記のリブにより、第１方向から見たときの第１平板（第２平板）の変形は抑えられる。しかしながら、上記のリブは、第２方向から見たときの第１平板（第２平板）の変形抑制には大きく寄与しない。本明細書は、積層ユニットの複数の第１端子（第２端子）とコンデンサを接続する第１バスバ（第２バスバ）の第１平板（第２平板）の変形（特に第２方向かみたときの変形）を抑える技術を提供する。 In the following, for convenience of explanation, a direction orthogonal to the first direction and parallel to the first flat plate will be referred to as a second direction. With the above ribs, deformation of the first flat plate (second flat plate) when viewed from the first direction is suppressed. However, the ribs do not significantly contribute to the suppression of deformation of the first flat plate (second flat plate) when viewed from the second direction. This specification describes the deformation (particularly when the second plate) of the first plate (second plate) of the first bus bar (second bus bar) connecting the capacitors to the plurality of first terminals (second terminals) of the laminated unit (especially when the second plate is bitten). We provide technology to suppress the deformation of).
　本明細書が開示する電力変換器は、複数のパワーモジュールが積層されている積層ユニットと、積層ユニットの隣りに配置されているコンデンサと、第１バスバと、第２バスバを備えている。それぞれのパワーモジュールは、電力変換用のスイッチング素子を収容している。スイッチング素子と導通している第１端子と第２端子が、パワーモジュールの側面から延びている。複数のパワーモジュールの第１端子は、パワーモジュールの積層方向（第１方向）に沿って一列に並んでおり、複数の第２端子は、第１端子の列と平行に一列に並んでいる。 The power converter disclosed in the present specification includes a laminated unit in which a plurality of power modules are laminated, a capacitor arranged next to the laminated unit, a first bus bar, and a second bus bar. Each power module contains a switching element for power conversion. The first terminal and the second terminal conducting with the switching element extend from the side surface of the power module. The first terminals of the plurality of power modules are arranged in a row along the stacking direction (first direction) of the power modules, and the plurality of second terminals are arranged in a row in parallel with the row of the first terminals.
　第１バスバは、複数のパワーモジュールの第１端子と接合しているとともに、コンデンサの一方の電極と接続している。第１バスバは、コンデンサからパワーモジュールの側面（第１端子と第２端子が設けられている側面）に沿って延びている第１平板を含んでいる。第１平板には、複数の第１孔と複数の第１枝部が設けられている。複数の第１孔のそれぞれを第１端子が通過する。それぞれの第１枝部は、それぞれの第１孔の縁から延びており、それぞれの第１端子と接続されている。 The first bus bar is connected to the first terminals of a plurality of power modules and is also connected to one electrode of the capacitor. The first bus bar includes a first flat plate extending from the capacitor along the side surface of the power module (the side surface where the first terminal and the second terminal are provided). The first flat plate is provided with a plurality of first holes and a plurality of first branch portions. The first terminal passes through each of the plurality of first holes. Each first branch extends from the edge of each first hole and is connected to each first terminal.
　第２バスバは、複数のパワーモジュールの第２端子と接合しているとともに、コンデンサの他方の電極と接続している。第２バスバは、コンデンサから第１平板と平行に延びている第２平板を含んでいる。第２平板には、複数の第２孔と複数の第２枝部が設けられている。複数の第２孔のそれぞれを第２端子が通過する。それぞれの第２枝部は、それぞれの第２孔の縁から延びており、それぞれの第２端子と接続されている。 The second bus bar is connected to the second terminal of a plurality of power modules and is connected to the other electrode of the capacitor. The second bus bar includes a second plate extending from the capacitor in parallel with the first plate. The second flat plate is provided with a plurality of second holes and a plurality of second branch portions. The second terminal passes through each of the plurality of second holes. Each second branch extends from the edge of each second hole and is connected to each second terminal.
　第１平板のコンデンサから遠い側の縁に第１リブが設けられている。この第１リブにより、第２方向からみたときの第１平板の変形が抑えられる。第２平板のコンデンサから遠い側の縁に第２リブが設けられていてもよい。第２リブは、第２方向からみたときの第２平板の変形を抑える。第１リブと第２リブは、第３方向に沿ってそれぞれの平板から延びている。第３方向は、第１方向と第２方向の両方に直交する方向である。第１リブと第２リブは、第３方向で互いに離間する方向に延びている。互いに離間する方向に延びる第１リブと第２リブは相互に干渉することがない。 The first rib is provided on the edge far from the capacitor of the first flat plate. Due to this first rib, the deformation of the first flat plate when viewed from the second direction is suppressed. A second rib may be provided on the edge far from the capacitor of the second flat plate. The second rib suppresses the deformation of the second flat plate when viewed from the second direction. The first rib and the second rib extend from the respective flat plates along the third direction. The third direction is a direction orthogonal to both the first direction and the second direction. The first rib and the second rib extend in a direction separated from each other in the third direction. The first rib and the second rib extending in the direction away from each other do not interfere with each other.
　本明細書が開示する技術の詳細とさらなる改良は以下の「発明を実施するための形態」にて説明する。 Details and further improvements of the techniques disclosed herein will be described in the "Modes for Carrying Out the Invention" below.
実施例の電力変換器を含む電気自動車の電力系のブロック図である。It is a block diagram of the electric power system of the electric vehicle including the electric power converter of an Example. 積層ユニットとバスバとコンデンサユニットのアセンブリの斜視図である。It is a perspective view of the assembly of a laminated unit, a bus bar and a capacitor unit. アセンブリの分解斜視図である。It is an exploded perspective view of an assembly. 変形例の電力変換器のアセンブリの斜視図である。It is a perspective view of the assembly of the power converter of a modification. 図４における切欠の近傍の拡大図である。It is an enlarged view of the vicinity of the notch in FIG.
　図面を参照して実施例の電力変換器を説明する。実施例の電力変換器は電気自動車に搭載されるデバイスである。電力変換器は、バッテリの電力を走行用モータの駆動電力に変換する。図１に、電力変換器２を含む電気自動車１００の電力系のブロック図を示す。電気自動車１００は、２個の走行用モータ８３ａ、８３ｂを備える。それゆえ、電力変換器２は、２セットのインバータ回路１３ａ、１３ｂを備える。なお、２個のモータ８３ａ、８３ｂの出力は、ギアボックス８５で合成／分配されて車軸８６（即ち駆動輪）へと伝達される。 The power converter of the embodiment will be described with reference to the drawings. The power converter of the embodiment is a device mounted on an electric vehicle. The power converter converts the power of the battery into the drive power of the traction motor. FIG. 1 shows a block diagram of an electric power system of an electric vehicle 100 including a power converter 2. The electric vehicle 100 includes two traveling motors 83a and 83b. Therefore, the power converter 2 includes two sets of inverter circuits 13a and 13b. The outputs of the two motors 83a and 83b are combined / distributed by the gearbox 85 and transmitted to the axle 86 (that is, the drive wheels).
　電力変換器２は、システムメインリレー８２を介してバッテリ８１と接続されている。電力変換器２は、バッテリ８１の電圧を昇圧する電圧コンバータ回路１２と、昇圧後の直流電力を交流に変換する２セットのインバータ回路１３ａ、１３ｂを備えている。 The power converter 2 is connected to the battery 81 via the system main relay 82. The power converter 2 includes a voltage converter circuit 12 that boosts the voltage of the battery 81, and two sets of inverter circuits 13a and 13b that convert the boosted DC power into alternating current.
　電圧コンバータ回路１２は、昇圧動作と降圧動作の双方を行うことが可能な双方向ＤＣ－ＤＣコンバータである。昇圧動作では、電圧コンバータ回路１２は、バッテリ側の端子に印加された電圧を昇圧してインバータ側の端子に出力する。降圧動作では、電圧コンバータ回路１２は、インバータ側の端子に印加された電圧を降圧してバッテリ側の端子に出力する。説明の便宜上、以下では、バッテリ側（低電圧側）の端子を入力端１８と称し、インバータ側（高電圧側）の端子を出力端１９と称する。また、入力端１８の正極と負極を夫々、入力正極端１８ａと入力負極端１８ｂと称する。出力端１９の正極と負極を夫々、出力正極端１９ａと出力負極端１９ｂと称する。「入力端１８」、「出力端１９」との表記は説明の便宜を図るためのものであり、先に述べたように、電圧コンバータ回路１２は双方向ＤＣ－ＤＣコンバータであるので、出力端１９から入力端１８へ電力が流れる場合がある。 The voltage converter circuit 12 is a bidirectional DC-DC converter capable of performing both step-up operation and step-down operation. In the boosting operation, the voltage converter circuit 12 boosts the voltage applied to the terminal on the battery side and outputs it to the terminal on the inverter side. In the step-down operation, the voltage converter circuit 12 steps down the voltage applied to the terminal on the inverter side and outputs it to the terminal on the battery side. For convenience of explanation, in the following, the terminal on the battery side (low voltage side) will be referred to as an input terminal 18, and the terminal on the inverter side (high voltage side) will be referred to as an output terminal 19. Further, the positive electrode and the negative electrode of the input end 18 are referred to as an input positive electrode end 18a and an input negative electrode end 18b, respectively. The positive electrode and the negative electrode of the output end 19 are referred to as an output positive electrode end 19a and an output negative electrode end 19b, respectively. The notations "input end 18" and "output end 19" are for convenience of explanation. As described above, since the voltage converter circuit 12 is a bidirectional DC-DC converter, the output end Power may flow from 19 to the input end 18.
　電圧コンバータ回路１２は、２個のスイッチング素子９ａ、９ｂの直列回路、リアクトル７、フィルタコンデンサ５、各スイッチング素子に逆並列に接続されているダイオードで構成されている。リアクトル７は、一端が入力正極端１８ａに接続されており、他端は直列回路の中点に接続されている。フィルタコンデンサ５は、入力正極端１８ａと入力負極端１８ｂの間に接続されている。入力負極端１８ｂは、出力負極端１９ｂと直接に接続されている。スイッチング素子９ｂが主に昇圧動作に関与し、スイッチング素子９ａが主に降圧動作に関与する。図１の電圧コンバータ回路１２はよく知られているので詳細な説明は省略する。 The voltage converter circuit 12 is composed of a series circuit of two switching elements 9a and 9b, a reactor 7, a filter capacitor 5, and a diode connected in antiparallel to each switching element. One end of the reactor 7 is connected to the input positive electrode end 18a, and the other end is connected to the midpoint of the series circuit. The filter capacitor 5 is connected between the input positive electrode end 18a and the input negative electrode end 18b. The input negative electrode end 18b is directly connected to the output negative electrode end 19b. The switching element 9b is mainly involved in the step-up operation, and the switching element 9a is mainly involved in the step-down operation. Since the voltage converter circuit 12 of FIG. 1 is well known, detailed description thereof will be omitted.
　符号８ａが示す破線矩形の範囲の回路が、後述するパワーモジュール８ａに対応する。符号２５ａ、２５ｂは、パワーモジュール８ａから延出している端子を示している。符号２５ａは、スイッチング素子９ａ、９ｂの直列回路の高電位側と導通している端子（正極端子２５ａ）を示している。符号２５ｂは、スイッチング素子９ａ、９ｂの直列回路の低電位側と導通している端子（負極端子２５ｂ）を表している。次に説明するように、正極端子２５ａ、負極端子２５ｂという表記は、他のパワーモジュールでも用いる。なお、２個のスイッチング素子の直列接続の中点に接続される端子は中点端子と称する。 The circuit in the range of the broken line rectangle indicated by the reference numeral 8a corresponds to the power module 8a described later. Reference numerals 25a and 25b indicate terminals extending from the power module 8a. Reference numeral 25a indicates a terminal (positive electrode terminal 25a) conducting with the high potential side of the series circuit of the switching elements 9a and 9b. Reference numeral 25b represents a terminal (negative electrode terminal 25b) conducting with the low potential side of the series circuit of the switching elements 9a and 9b. As will be described next, the notation of positive electrode terminal 25a and negative electrode terminal 25b is also used in other power modules. The terminal connected to the midpoint of the series connection of the two switching elements is referred to as a midpoint terminal.
　インバータ回路１３ａは、２個のスイッチング素子の直列回路が３セット並列に接続された構成を有している。スイッチング素子９ｃと９ｄ、スイッチング素子９ｅと９ｆ、スイッチング素子９ｇと９ｈがそれぞれ直列回路を構成している。各スイッチング素子にはダイオードが逆並列に接続されている。３セットの直列回路の高電位側の端子（正極端子２５ａ）が電圧コンバータ回路１２の出力正極端１９ａに接続されており、３セットの直列回路の低電位側の端子（負極端子２５ｂ）が電圧コンバータ回路１２の出力負極端１９ｂに接続されている。３セットの直列回路の中点端子から３相交流（Ｕ相、Ｖ相、Ｗ相）が出力される。３セットの直列回路の夫々が、後述するパワーモジュール８ｂ、８ｃ、８ｄに対応する。 The inverter circuit 13a has a configuration in which three sets of series circuits of two switching elements are connected in parallel. The switching elements 9c and 9d, the switching elements 9e and 9f, and the switching elements 9g and 9h form a series circuit, respectively. Diodes are connected in anti-parallel to each switching element. The high potential side terminal (positive electrode terminal 25a) of the three sets of series circuits is connected to the output positive electrode end 19a of the voltage converter circuit 12, and the low potential side terminal (negative electrode terminal 25b) of the three sets of series circuits is voltage. It is connected to the output negative electrode end 19b of the converter circuit 12. Three-phase alternating current (U phase, V phase, W phase) is output from the midpoint terminal of the three sets of series circuits. Each of the three sets of series circuits corresponds to the power modules 8b, 8c, and 8d described later.
　インバータ回路１３ｂの構成はインバータ回路１３ａと同じであるため、図１では具体的な回路の図示を省略している。インバータ回路１３ｂもインバータ回路１３ａと同様に、２個のスイッチング素子の直列回路が３セット並列に接続された構成を有している。３セットの直列回路の高電位側の端子が電圧コンバータ回路１２の出力正極端１９ａに接続されており、３セットの直列回路の低電位側の端子が電圧コンバータ回路１２の出力負極端１９ｂに接続されている。各直列回路に対応するハードウエアをパワーモジュール８ｅ、８ｆ、８ｇと称する。 Since the configuration of the inverter circuit 13b is the same as that of the inverter circuit 13a, the specific circuit is not shown in FIG. Similar to the inverter circuit 13a, the inverter circuit 13b also has a configuration in which three sets of series circuits of two switching elements are connected in parallel. The terminal on the high potential side of the three sets of series circuits is connected to the output positive end 19a of the voltage converter circuit 12, and the terminal on the low potential side of the three sets of series circuits is connected to the output negative end 19b of the voltage converter circuit 12. Has been done. The hardware corresponding to each series circuit is referred to as a power module 8e, 8f, 8g.
　インバータ回路１３ａ、１３ｂの入力端に平滑コンデンサ６が並列に接続されている。平滑コンデンサ６は、別言すれば、電圧コンバータ回路１２の出力端１９に並列に接続されている。平滑コンデンサ６は、電圧コンバータ回路１２の出力電流の脈動を除去する。 A smoothing capacitor 6 is connected in parallel to the input ends of the inverter circuits 13a and 13b. In other words, the smoothing capacitor 6 is connected in parallel to the output terminal 19 of the voltage converter circuit 12. The smoothing capacitor 6 eliminates the pulsation of the output current of the voltage converter circuit 12.
　スイッチング素子９ａ－９ｈは、トランジスタであり、典型的にはＩＧＢＴ（Insulated Gate Bipolar Transistor）であるが、他のトランジスタ、例えば、ＭＯＳＦＥＴ（Metal Oxide Semiconductor Field Effect Transistor）であってもよい。また、ここでいうスイッチング素子は、電力変換に用いられるものであり、パワー半導体素子と呼ばれることもある。 The switching elements 9a-9h are transistors, typically IGBTs (Insulated Gate Bipolar Transistors), but may be other transistors, for example, MOSFETs (Metal Oxide Semiconductor Field Effect Transistors). Further, the switching element referred to here is used for power conversion, and is sometimes called a power semiconductor element.
　図１において、破線８ａ－８ｇの夫々がパワーモジュールに相当する。電力変換器２は、２個のスイッチング素子の直列回路を７セット備えている。ハードウエアとしては、直列回路を構成する２個のスイッチング素子、および各スイッチング素子に逆並列に接続されているダイオードが一つのパッケージ（パワーモジュールの本体）に収容されている。以下では、パワーモジュール８ａ－８ｇのいずれか一つを区別なく示すときにはパワーモジュール８と表記する。 In FIG. 1, each of the broken lines 8a-8g corresponds to the power module. The power converter 2 includes seven sets of a series circuit of two switching elements. As hardware, two switching elements constituting a series circuit and a diode connected in antiparallel to each switching element are housed in one package (main body of a power module). In the following, when any one of the power modules 8a to 8g is shown without distinction, it is referred to as the power module 8.
　７個のパワーモジュール（７セットの直列回路）の高電位側の端子（正極端子２５ａ）が平滑コンデンサ６の正電極に接続され、低電位側の端子（負極端子２５ｂ）が平滑コンデンサ６の負電極に接続される。図１において、符号３０が示す破線内の導電経路は、複数のパワーモジュール８の正極端子２５ａと平滑コンデンサ６の正電極を相互に接続するバスバ（正極バスバ）に対応する。符号４０が示す破線内の導電経路は、複数の負極端子２５ｂと平滑コンデンサ６の負電極を相互に接続するバスバ（負極バスバ）に対応する。次に、複数のパワーモジュール８と正極バスバ３０、負極バスバ４０の構造について説明する。 The high potential side terminal (positive electrode terminal 25a) of the seven power modules (7 sets of series circuits) is connected to the positive electrode of the smoothing capacitor 6, and the low potential side terminal (negative electrode terminal 25b) is the negative of the smoothing capacitor 6. Connected to the electrode. In FIG. 1, the conductive path in the broken line indicated by reference numeral 30 corresponds to a bus bar (positive electrode bus bar) that connects the positive electrode terminals 25a of the plurality of power modules 8 and the positive electrodes of the smoothing capacitor 6 to each other. The conductive path in the broken line indicated by reference numeral 40 corresponds to a bus bar (negative electrode bus bar) that connects the plurality of negative electrode terminals 25b and the negative electrodes of the smoothing capacitor 6 to each other. Next, the structures of the plurality of power modules 8, the positive electrode bus bar 30, and the negative electrode bus bar 40 will be described.
　図２に、電力変換器２のハードウエアの斜視図を示す。なお、図２では、電力変換器２のハウジングと一部の部品の図示を省略している。複数のパワーモジュール８（８ａ－８ｇ）は、複数の冷却器２２とともに積層ユニット２０を構成している。パワーモジュール８ａ－８ｇは全て同じ形状であるので、図２と図３では、左端のパワーモジュールにのみ、符号８を付し、他のパワーモジュールには符号を省略した。また、図２と図３では、左端の２個の冷却器にのみ、符号２２を付し、他の冷却器には符号を省略した。図３については後述する。 FIG. 2 shows a perspective view of the hardware of the power converter 2. In FIG. 2, the housing of the power converter 2 and some parts are not shown. The plurality of power modules 8 (8a-8g) together with the plurality of coolers 22 constitute a stacking unit 20. Since the power modules 8a-8g all have the same shape, in FIGS. 2 and 3, only the leftmost power module is designated by reference numeral 8, and the other power modules are designated by reference numerals. Further, in FIGS. 2 and 3, the reference numerals 22 are attached only to the two leftmost coolers, and the reference numerals are omitted for the other coolers. FIG. 3 will be described later.
　図２は、電力変換器２の斜視図であるが、積層ユニット２０、正極バスバ３０、負極バスバ４０、及び、コンデンサユニット６０のアセンブリのみを描いてあり、他の部品は図示を省略した。積層ユニット２０において、複数のパワーモジュール８は積層されている。積層ユニット２０は、複数のカードタイプの冷却器２２が平行に配置されているとともに、隣り合う冷却器２２の間にカードタイプのパワーモジュール８が挟まれているデバイスである。カードタイプのパワーモジュール８は、その幅広面を冷却器２２に対向させている。図中の座標系のＸ方向が複数のパワーモジュール８の積層方向に相当する。以降の図でも、Ｘ方向が積層方向を示す。 FIG. 2 is a perspective view of the power converter 2, but only the assembly of the laminated unit 20, the positive electrode bus bar 30, the negative electrode bus bar 40, and the capacitor unit 60 is drawn, and the other parts are not shown. In the stacking unit 20, a plurality of power modules 8 are laminated. The stacking unit 20 is a device in which a plurality of card-type coolers 22 are arranged in parallel, and a card-type power module 8 is sandwiched between adjacent coolers 22. The card-type power module 8 has its wide surface facing the cooler 22. The X direction of the coordinate system in the figure corresponds to the stacking direction of the plurality of power modules 8. In the following figures, the X direction also indicates the stacking direction.
　各パワーモジュール８の一つの側面８０ａから３個の端子（正極端子２５ａ、負極端子２５ｂ、中点端子２５ｃ）が延びている。図２と図３では、積層ユニット２０の左端に位置するパワーモジュール８の端子にのみ符号２５ａ、２５ｂ、２５ｃを付し、残りのパワーモジュール８には端子を示す符号を省略した。 Three terminals (positive electrode terminal 25a, negative electrode terminal 25b, midpoint terminal 25c) extend from one side surface 80a of each power module 8. In FIGS. 2 and 3, reference numerals 25a, 25b, and 25c are attached only to the terminals of the power module 8 located at the left end of the stacking unit 20, and the reference numerals indicating the terminals are omitted from the remaining power modules 8.
　正極端子２５ａと負極端子２５ｂは、先に述べたように、パワーモジュール８に収容されている直列回路の高電位側の端子と低電位側の端子である。中点端子２５ｃは、直列回路の中点と導通している端子である。別言すれば、３個の端子２５ａ－２５ｃは、いずれも、パワーモジュール８の内部でスイッチング素子と導通している。３個の端子２５ａ－２５ｃは、パワーモジュール８の幅広面と交差する一側面８０ａから図中のＺ軸正方向に延びている。一側面８０ａの反対側の側面から複数の制御端子が図中のＺ軸負方向に延びている。制御端子は、パワーモジュール８に内蔵されているスイッチング素子のゲート電極と導通しているゲート端子、及び、パワーモジュール８に内蔵されている温度センサや電流センサと導通している信号端子などである。 As described above, the positive electrode terminal 25a and the negative electrode terminal 25b are a terminal on the high potential side and a terminal on the low potential side of the series circuit housed in the power module 8. The midpoint terminal 25c is a terminal conducting with the midpoint of the series circuit. In other words, all three terminals 25a-25c are conducting with the switching element inside the power module 8. The three terminals 25a-25c extend in the positive direction of the Z axis in the drawing from one side surface 80a intersecting the wide surface of the power module 8. A plurality of control terminals extend in the negative direction of the Z axis in the drawing from the side surface opposite to one side surface 80a. The control terminals are a gate terminal conducting with the gate electrode of the switching element built in the power module 8, a signal terminal conducting with the temperature sensor and the current sensor built in the power module 8, and the like. ..
　図中の右端の冷却器２２には、冷媒供給口２８と冷媒排出口２９が設けられている。隣接する冷却器２２同士は、２個の連結管で接続されている。一方の連結管は、積層方向からみて冷媒供給口２８と重なるように位置している。他方の連結管は、積層方向からみて冷媒排出口２９と重なるように位置している。冷媒供給口２８と冷媒排出口２９には、不図示の冷媒循環装置が接続される。冷媒供給口２８から供給される冷媒は、一方の連結管を通じて全ての冷却器２２に分配される。冷媒は冷却器２２を通る間に隣接するパワーモジュール８から熱を吸収する。熱を吸収した冷媒は、他方の連結管と冷媒排出口２９を通じて積層ユニット２０から排出される。各パワーモジュール８は、その両側から冷却されるので、積層ユニット２０は冷却性能が高い。 The rightmost cooler 22 in the figure is provided with a refrigerant supply port 28 and a refrigerant discharge port 29. The adjacent coolers 22 are connected by two connecting pipes. One connecting pipe is positioned so as to overlap the refrigerant supply port 28 when viewed from the stacking direction. The other connecting pipe is positioned so as to overlap the refrigerant discharge port 29 when viewed from the stacking direction. A refrigerant circulation device (not shown) is connected to the refrigerant supply port 28 and the refrigerant discharge port 29. The refrigerant supplied from the refrigerant supply port 28 is distributed to all the coolers 22 through one connecting pipe. The refrigerant absorbs heat from the adjacent power module 8 while passing through the cooler 22. The heat-absorbed refrigerant is discharged from the stacking unit 20 through the other connecting pipe and the refrigerant discharge port 29. Since each power module 8 is cooled from both sides thereof, the laminated unit 20 has high cooling performance.
　各パワーモジュール８の３個の端子２５ａ－２５ｃはいずれも平板状である。複数のパワーモジュール８の正極端子２５ａは、隣接するパワーモジュール８の正極端子２５ａの平坦面と対向するように、Ｘ方向（積層方向）に一列に並んでいる。複数のパワーモジュール８の負極端子２５ｂも、隣接するパワーモジュール８の負極端子２５ｂの平坦面と対向するように、Ｘ方向（積層方向）に一列に並んでいる。複数のパワーモジュール８の中点端子２５ｃも同様である。複数のパワーモジュール８の正極端子２５ａの列と、負極端子２５ｂの列と、中点端子２５ｃの列は、平行である。 The three terminals 25a-25c of each power module 8 are all flat plates. The positive electrode terminals 25a of the plurality of power modules 8 are arranged in a row in the X direction (stacking direction) so as to face the flat surface of the positive electrode terminals 25a of the adjacent power modules 8. The negative electrode terminals 25b of the plurality of power modules 8 are also arranged in a row in the X direction (stacking direction) so as to face the flat surface of the negative electrode terminals 25b of the adjacent power modules 8. The same applies to the midpoint terminals 25c of the plurality of power modules 8. The rows of the positive electrode terminals 25a, the rows of the negative electrode terminals 25b, and the rows of the midpoint terminals 25c of the plurality of power modules 8 are parallel.
　積層ユニット２０の横にコンデンサユニット６０が配置されている。コンデンサユニット６０は、パワーモジュール８の積層方向（図中のＸ方向）に沿って長い。コンデンサユニット６０は、積層方向と交差する方向（Ｙ方向）で積層ユニット２０と並んでいる。コンデンサユニット６０のケースの中には、２個のコンデンサ素子６１（後述）が収容されている。正極バスバ３０は、複数のパワーモジュール８の夫々の正極端子２５ａと、コンデンサユニット６０の中のコンデンサ素子を接続しており、負極バスバ４０は、複数のパワーモジュール８の夫々の負極端子２５ｂとコンデンサユニット６０の中のコンデンサ素子を接続する。 The capacitor unit 60 is arranged next to the laminated unit 20. The capacitor unit 60 is long along the stacking direction (X direction in the figure) of the power module 8. The capacitor unit 60 is aligned with the stacking unit 20 in a direction (Y direction) intersecting the stacking direction. Two capacitor elements 61 (described later) are housed in the case of the capacitor unit 60. The positive electrode bus bar 30 connects the positive electrode terminals 25a of the plurality of power modules 8 to the capacitor elements in the capacitor unit 60, and the negative electrode bus bar 40 connects the negative electrode terminals 25b of the plurality of power modules 8 to the capacitors. The capacitor element in the unit 60 is connected.
　図３に、正極バスバ３０と負極バスバ４０と積層ユニット２０とコンデンサ素子６１（コンデンサユニット６０）のアセンブリの分解斜視図を示す。なお、図２のコンデンサユニット６０には、２個のコンデンサ素子６１が収容されている。図３では、コンデンサユニット６０のケースを省略し、内部のコンデンサ素子６１を描いてある。詳細は割愛するが、コンデンサユニット６０のケースの中でコンデンサ素子６１の周囲は充填材で満たされている。コンデンサ素子６１は、図１の平滑コンデンサ６に相当する。 FIG. 3 shows an exploded perspective view of the assembly of the positive electrode bus bar 30, the negative electrode bus bar 40, the laminated unit 20, and the capacitor element 61 (capacitor unit 60). The capacitor unit 60 of FIG. 2 accommodates two capacitor elements 61. In FIG. 3, the case of the capacitor unit 60 is omitted, and the internal capacitor element 61 is drawn. Although details are omitted, the periphery of the capacitor element 61 in the case of the capacitor unit 60 is filled with a filler. The capacitor element 61 corresponds to the smoothing capacitor 6 in FIG.
　複数のパワーモジュール８の正極端子２５ａとコンデンサ素子６１の正電極６１ａが正極バスバ３０で接続され、複数の負極端子２５ｂとコンデンサ素子６１の負電極６１ｂが負極バスバ４０で接続される。 The positive electrode 25a of the plurality of power modules 8 and the positive electrode 61a of the capacitor element 61 are connected by the positive electrode bus bar 30, and the plurality of negative electrode terminals 25b and the negative electrode 61b of the capacitor element 61 are connected by the negative electrode bus bar 40.
　正極バスバ３０は、板状の電極部３９と平板３１を備えている。平板３１には、複数の正極端子孔３２と複数の枝部３３が設けられている。電極部３９が、コンデンサ素子６１の正電極６１ａに接続される。複数の正極端子孔３２は、Ｘ方向に沿って一列に並んでいる。それぞれの正極端子孔３２の縁から枝部３３がＺ方向に延びている。それぞれの正極端子孔３２を対応するパワーモジュール８の正極端子２５ａが通り、その正極端子２５ａと枝部３３が溶接にて接合される。 The positive electrode bus bar 30 includes a plate-shaped electrode portion 39 and a flat plate 31. The flat plate 31 is provided with a plurality of positive electrode terminal holes 32 and a plurality of branch portions 33. The electrode portion 39 is connected to the positive electrode 61a of the capacitor element 61. The plurality of positive electrode terminal holes 32 are arranged in a row along the X direction. A branch portion 33 extends in the Z direction from the edge of each positive electrode terminal hole 32. The positive electrode terminal 25a of the power module 8 corresponding to each positive electrode terminal hole 32 passes through, and the positive electrode terminal 25a and the branch portion 33 are joined by welding.
　負極バスバ４０は、板状の電極部４９と平板４１を備えている。平板４１には、複数の負極端子孔４２と複数の枝部４３が設けられている。電極部４９が、コンデンサ素子６１の負電極６１ｂに接続される。複数の負極端子孔４２は、Ｘ方向に沿って一列に並んでいる。それぞれの負極端子孔４２の縁から枝部４３がＺ方向に延びている。それぞれの負極端子孔４２を対応するパワーモジュール８の負極端子２５ｂが通り、その負極端子２５ｂと枝部４３が接合される。 The negative electrode bus bar 40 includes a plate-shaped electrode portion 49 and a flat plate 41. The flat plate 41 is provided with a plurality of negative electrode terminal holes 42 and a plurality of branch portions 43. The electrode portion 49 is connected to the negative electrode 61b of the capacitor element 61. The plurality of negative electrode terminal holes 42 are arranged in a row along the X direction. A branch portion 43 extends in the Z direction from the edge of each negative electrode terminal hole 42. The negative electrode terminal 25b of the power module 8 corresponding to each negative electrode terminal hole 42 passes through, and the negative electrode terminal 25b and the branch portion 43 are joined.
　負極バスバ４０は、正極バスバ３０の積層ユニット２０とは反対側に位置している。負極バスバ４０には、複数の正極端子孔４５が設けられている。それぞれの正極端子孔４５を、パワーモジュール８の正極端子２５ａと、正極バスバ３０の枝部３３が通過する。正極バスバ３０の平板３１と、負極バスバ４０の平板４１は、絶縁板５０（後述）を挟んで平行に配置されているとともに、相互に近接対向している。一方のバスバに電流が流れると、その電流に起因してバスバの周囲に磁界が発生する。磁界の大きさとバスバのインダクタンスには正の相関がある。磁界が大きいほど、インダクタンスも大きくなる。正極バスバ３０の平板３１と負極バスバ４０の平板４１が近接対向していると、一方のバスバの磁界によって他方のバスバに渦電流が生じる。渦電流の発生は、一方のバスバの磁界を弱める。磁界が弱まるということは、インダクタンスが小さくなることを意味する。バスバの平板３１、４１を近接配置することで、バスバのインダクタンスを小さくすることができる。 The negative electrode bus bar 40 is located on the opposite side of the laminated unit 20 of the positive electrode bus bar 30. The negative electrode bus bar 40 is provided with a plurality of positive electrode terminal holes 45. The positive electrode terminal 25a of the power module 8 and the branch portion 33 of the positive electrode bus bar 30 pass through each of the positive electrode terminal holes 45. The flat plate 31 of the positive electrode bus bar 30 and the flat plate 41 of the negative electrode bus bar 40 are arranged in parallel with the insulating plate 50 (described later) interposed therebetween and are close to each other. When a current flows through one of the bus bars, a magnetic field is generated around the bus bar due to the current. There is a positive correlation between the magnitude of the magnetic field and the inductance of the bus bar. The larger the magnetic field, the larger the inductance. When the flat plate 31 of the positive electrode bus bar 30 and the flat plate 41 of the negative electrode bus bar 40 are in close contact with each other, an eddy current is generated in the other bus bar by the magnetic field of one bus bar. The generation of eddy currents weakens the magnetic field of one bus bar. The weakening of the magnetic field means that the inductance becomes smaller. By arranging the flat plates 31 and 41 of the bus bar close to each other, the inductance of the bus bar can be reduced.
　正極バスバ３０と負極バスバ４０の間に絶縁板５０が挟まれている。絶縁板５０は、正極バスバ３０と負極バスバ４０の間を絶縁する。絶縁板５０には、複数の筒部５３が設けられている。絶縁板５０の積層方向（Ｘ方向）の両側には、Ｙ方向に延びているリブ５７が設けられている。図２に示されているように、リブ５７は、正極バスバ３０の補強リブ３７と負極バスバ４０の補強リブ４７の間に挟まれ、両者を絶縁する。補強リブ３７、４７については後述する。 The insulating plate 50 is sandwiched between the positive electrode bus bar 30 and the negative electrode bus bar 40. The insulating plate 50 insulates between the positive electrode bus bar 30 and the negative electrode bus bar 40. The insulating plate 50 is provided with a plurality of tubular portions 53. Ribs 57 extending in the Y direction are provided on both sides of the insulating plate 50 in the stacking direction (X direction). As shown in FIG. 2, the rib 57 is sandwiched between the reinforcing rib 37 of the positive electrode bus bar 30 and the reinforcing rib 47 of the negative electrode bus bar 40 to insulate both of them. Reinforcing ribs 37 and 47 will be described later.
　絶縁板５０の筒部５３は、負極バスバ４０の正極端子孔４５を通過している。筒部５３の内部を、正極バスバ３０の枝部３３と、パワーモジュール８の正極端子２５ａが通過する。筒部５３は、正極端子２５ａと枝部３３を負極バスバ４０から確実に絶縁する。 The tubular portion 53 of the insulating plate 50 passes through the positive electrode terminal hole 45 of the negative electrode bus bar 40. The branch portion 33 of the positive electrode bus bar 30 and the positive electrode terminal 25a of the power module 8 pass through the inside of the tubular portion 53. The tubular portion 53 reliably insulates the positive electrode terminal 25a and the branch portion 33 from the negative electrode bus bar 40.
　正極バスバ３０の平板３１の積層方向（Ｘ方向）の両端は、直角に折り曲げられている。直角に折り曲げられた部分を補強リブ３７と称する。負極バスバ４０の平板４１の積層方向（Ｘ方向）の両端も、直角に折り曲げられている。直角に折り曲げられた部分を補強リブ４７と称する。先に述べたように、コンデンサ素子６１は、ケースに収容されるとともに、ケースの中で充填材に埋設される。従って、正極バスバ３０の一部と負極バスバ４０の一部もコンデンサユニット６０のケースの中で充填材に埋設される。当然、電極部３９、４９は、充填材に埋設されることになる。正極バスバ３０の平板３１の一部３１ａも充填材に埋設され、負極バスバ４０の平板４１の一部４１ａも充填材に埋設される。符号３１ｂ、４１ｂが示す箇所は、平板３１、４１のなかでコンデンサユニット６０から露出する露出部である。補強リブ３７の一部３７ａ、補強リブ４７の一部４７ａも、充填材に埋設される。 Both ends of the flat plate 31 of the positive electrode bus bar 30 in the stacking direction (X direction) are bent at right angles. The portion bent at a right angle is referred to as a reinforcing rib 37. Both ends of the flat plate 41 of the negative electrode bus bar 40 in the stacking direction (X direction) are also bent at right angles. The portion bent at a right angle is referred to as a reinforcing rib 47. As described above, the capacitor element 61 is housed in the case and is embedded in the filler in the case. Therefore, a part of the positive electrode bus bar 30 and a part of the negative electrode bus bar 40 are also embedded in the filler in the case of the capacitor unit 60. Naturally, the electrode portions 39 and 49 will be embedded in the filler. A part 31a of the flat plate 31 of the positive electrode bus bar 30 is also embedded in the filler, and a part 41a of the flat plate 41 of the negative electrode bus bar 40 is also embedded in the filler. The portion indicated by reference numerals 31b and 41b is an exposed portion exposed from the capacitor unit 60 in the flat plates 31 and 41. A part 37a of the reinforcing rib 37 and a part 47a of the reinforcing rib 47 are also embedded in the filler.
　正極バスバ３０（平板３１）のコンデンサ素子６１から最も遠い側の縁にも補強リブ３８が設けられている。補強リブ３８は、平板３１のＸ方向に延びる２個の縁のうち、コンデンサ素子６１から遠い側の縁に設けられている。負極バスバ４０（平板４１）のコンデンサ素子６１から遠い側の縁にも補強リブ４８が設けられている。補強リブ４８は、平板４１のＸ方向に延びる２個の縁のうち、コンデンサ素子６１から遠い側の縁に設けられている。 Reinforcing ribs 38 are also provided on the edge of the positive electrode bus bar 30 (flat plate 31) farthest from the condenser element 61. The reinforcing rib 38 is provided on the edge of the flat plate 31 extending in the X direction on the side farther from the capacitor element 61. Reinforcing ribs 48 are also provided on the edge of the negative electrode bus bar 40 (flat plate 41) on the side far from the capacitor element 61. The reinforcing rib 48 is provided on the edge of the flat plate 41 extending in the X direction on the side farther from the capacitor element 61.
　補強リブ３８は、平板３１からーＺ方向に延びている。補強リブ４８は、平板４１から＋Ｚ方向に延びている。すなわち、補強リブ３８と補強リブ４８は、互いに離れる方向に延びている。それゆえ、正極バスバ３０と負極バスバ４０が重なっていても、補強リブ３８と補強リブ４８が干渉することはない。 The reinforcing rib 38 extends from the flat plate 31 in the -Z direction. The reinforcing rib 48 extends from the flat plate 41 in the + Z direction. That is, the reinforcing rib 38 and the reinforcing rib 48 extend in a direction away from each other. Therefore, even if the positive electrode bus bar 30 and the negative electrode bus bar 40 overlap, the reinforcing rib 38 and the reinforcing rib 48 do not interfere with each other.
　先に述べた補強リブ３７は、正極バスバ３０（平板３１）をＸ方向からみたときの曲げに対する剛性を高める。別言すれば、補強リブ３７は、Ｘ方向に延びる軸回りの正極バスバ３０（平板３１）の変形を抑制する。一方、補強リブ３８は、正極バスバ３０（平板３１）をＹ方向からみたときの曲げに対する剛性を高める。別言すれば、補強リブ３８は、Ｙ方向に延びる軸回りの正極バスバ３０（平板３１）の変形を抑制する。 The reinforcing rib 37 described above increases the rigidity of the positive electrode bus bar 30 (flat plate 31) against bending when viewed from the X direction. In other words, the reinforcing rib 37 suppresses the deformation of the positive electrode bus bar 30 (flat plate 31) around the axis extending in the X direction. On the other hand, the reinforcing rib 38 increases the rigidity of the positive electrode bus bar 30 (flat plate 31) against bending when viewed from the Y direction. In other words, the reinforcing rib 38 suppresses the deformation of the positive electrode bus bar 30 (flat plate 31) around the axis extending in the Y direction.
　補強リブ４７も同様である。補強リブ４７は、負極バスバ４０（平板４１）をＸ方向からみたときの曲げに対する剛性を高める。別言すれば、補強リブ４７は、Ｘ方向に延びる軸回りの負極バスバ４０（平板４１）の変形を抑制する。補強リブ４８は、負極バスバ４０（平板４１）をＹ方向からみたときの曲げに対する剛性を高める。別言すれば、補強リブ４８は、Ｙ方向に延びる軸回りの負極バスバ４０（平板４１）の変形を抑制する。 The same applies to the reinforcing rib 47. The reinforcing rib 47 increases the rigidity of the negative electrode bus bar 40 (flat plate 41) against bending when viewed from the X direction. In other words, the reinforcing rib 47 suppresses deformation of the negative electrode bus bar 40 (flat plate 41) around the axis extending in the X direction. The reinforcing rib 48 increases the rigidity of the negative electrode bus bar 40 (flat plate 41) against bending when viewed from the Y direction. In other words, the reinforcing rib 48 suppresses deformation of the negative electrode bus bar 40 (flat plate 41) around the axis extending in the Y direction.
　電力変換器２の製造工程において、正極バスバ３０の枝部３３がパワーモジュール８の正極端子２５ａと接合される。接合の際、枝部３３と正極端子２５ａがチャックで掴まれる。チャックから受ける力により、正極バスバ３０の平板３１が変形するおそれがある。補強リブ３８は、チャックの力に起因する平板３１の変形を抑える。負極バスバ４０についても同様であり、補強リブ４８は、チャックの力（枝部４３と負極端子２５ｂを挟む力）に起因する平板４１の変形を抑える。 In the manufacturing process of the power converter 2, the branch portion 33 of the positive electrode bus bar 30 is joined to the positive electrode terminal 25a of the power module 8. At the time of joining, the branch portion 33 and the positive electrode terminal 25a are gripped by the chuck. The flat plate 31 of the positive electrode bus bar 30 may be deformed by the force received from the chuck. The reinforcing rib 38 suppresses deformation of the flat plate 31 due to the force of the chuck. The same applies to the negative electrode bus bar 40, and the reinforcing rib 48 suppresses the deformation of the flat plate 41 due to the force of the chuck (the force sandwiching the branch portion 43 and the negative electrode terminal 25b).
　補強リブ３７、３８は、一枚の平板（平板３１）を折り曲げて作られる。補強リブ４７、４８は、一枚の平板（平板４１）を折り曲げて作られる。 Reinforcing ribs 37 and 38 are made by bending one flat plate (flat plate 31). The reinforcing ribs 47 and 48 are made by bending one flat plate (flat plate 41).
　図４に、変形例の電力変換器２ａの斜視図を示す。図４は、図２に対応する。なお、図４では、複数のパワーモジュール８のそれぞれに固有の符号（８ａ－８ｇ）を付してある。 FIG. 4 shows a perspective view of a modified power converter 2a. FIG. 4 corresponds to FIG. In FIG. 4, each of the plurality of power modules 8 is given a unique reference numeral (8a-8g).
　変形例の電力変換器２ａの補強リブ１３８と補強リブ１４８は、実施例の電力変換器２の補強リブ３８、４８と相違する。補強リブ１３８、１４８を除いて、電力変換器２ａの構造は電力変換器２の構造と同じである。 The reinforcing ribs 138 and 148 of the power converter 2a of the modified example are different from the reinforcing ribs 38 and 48 of the power converter 2 of the embodiment. The structure of the power converter 2a is the same as that of the power converter 2 except for the reinforcing ribs 138 and 148.
　補強リブ１４８は、２カ所の切欠１４９ａ、１４９ｂを有している。図５に、切欠１４９ａの近傍の拡大図を示してある。切欠１４９ａ、１４９ｂは、負極端子孔４２に達している。先に述べたように、補強リブ１４８は、Ｙ方向からみたときの平板４１の変形を抑える。一方、補強リブ１４８を設けることで、平板４１の剛性が高くなり、力を受けたときに局所的に応力が集中するおそれがある。切欠１４９ａ、１４９ｂを設けることで平板４１が力を受けたときの応力集中が緩和される。 Reinforcing rib 148 has two notches 149a and 149b. FIG. 5 shows an enlarged view of the vicinity of the notch 149a. The notches 149a and 149b reach the negative electrode terminal hole 42. As described above, the reinforcing rib 148 suppresses the deformation of the flat plate 41 when viewed from the Y direction. On the other hand, by providing the reinforcing rib 148, the rigidity of the flat plate 41 is increased, and stress may be locally concentrated when a force is applied. By providing the notches 149a and 149b, the stress concentration when the flat plate 41 receives a force is relaxed.
　また、切欠１４９ａは、パワーモジュール８ａとパワーモジュール８ｂの間に設けられている。より詳しくは、切欠１４９ａは、パワーモジュール８ａの中点端子２５ｃとパワーモジュール８ｂの中点端子２５ｃの間に設けられている。図１を用いて説明したように、パワーモジュール８ａは電圧コンバータ回路１２に用いられており、パワーモジュール８ｂはインバータ回路１３ａに用いられている。すなわち、切欠１４９ａは、異なる変換回路に用いられている２個のパワーモジュール８ａ、８ｂの間に設けられている。パワーモジュール８ａ、８ｂのスイッチング素子は相互に独立したタイミングで動作し、スイッチングノイズが互いに干渉する。切欠１４９ａは、相互に独立したタイミングで動作するスイッチング素子のノイズの干渉を低減する。 Further, the notch 149a is provided between the power module 8a and the power module 8b. More specifically, the notch 149a is provided between the midpoint terminal 25c of the power module 8a and the midpoint terminal 25c of the power module 8b. As described with reference to FIG. 1, the power module 8a is used in the voltage converter circuit 12, and the power module 8b is used in the inverter circuit 13a. That is, the notch 149a is provided between the two power modules 8a and 8b used in different conversion circuits. The switching elements of the power modules 8a and 8b operate at timings independent of each other, and switching noise interferes with each other. The notch 149a reduces noise interference from switching elements that operate at mutually independent timings.
　切欠１４９ｂはパワーモジュール８ｄとパワーモジュール８ｅの間に設けられている。より詳しくは、切欠１４９ｂは、パワーモジュール８ｄの中点端子２５ｃとパワーモジュール８ｅの中点端子２５ｃの間に設けられている。パワーモジュール８ｄはインバータ回路１３ａに用いられており、パワーモジュール８ｅはインバータ回路１３ｂに用いられている。パワーモジュール８ｄ、８ｅのスイッチング素子は相互に独立したタイミングで動作し、スイッチングノイズが互いに干渉する。切欠１４９ｂも、相互に独立したタイミングで動作するスイッチング素子のノイズの干渉を低減する。 The notch 149b is provided between the power module 8d and the power module 8e. More specifically, the notch 149b is provided between the midpoint terminal 25c of the power module 8d and the midpoint terminal 25c of the power module 8e. The power module 8d is used in the inverter circuit 13a, and the power module 8e is used in the inverter circuit 13b. The switching elements of the power modules 8d and 8e operate at timings independent of each other, and switching noise interferes with each other. The notch 149b also reduces noise interference from switching elements that operate at mutually independent timings.
　図４では隠れて見えないが、正極バスバ３０の補強リブ１３８にも同様の切欠が設けられている。補強リブ１３８に設けられた切欠も、補強リブ１４８の切欠１４９ａ、１４９ｂと同じ効果を奏する。 Although it is hidden and invisible in FIG. 4, a similar notch is provided in the reinforcing rib 138 of the positive electrode bus bar 30. The notch provided in the reinforcing rib 138 has the same effect as the notch 149a and 149b of the reinforcing rib 148.
　実施例で説明した技術に関する留意点を述べる。実施例の負極バスバ４０が第１バスバの一例に相当する。負極バスバ４０の平板４１、負極端子孔４２、枝部４３のそれぞれが、第１平板、第１孔、第１枝部の一例に相当する。実施例の正極バスバ３０が第２バスバの一例に相当する。正極バスバ３０の平板３１、正極端子孔３２、枝部３３のそれぞれが、第２平板、第２孔、第２枝部の一例に相当する。補強リブ４８が第１リブの一例に相当する。補強リブ３８が第２リブの一例に相当する。図中の座標系のＸ方向が第１方向に相当し、Ｙ方向が第２方向に相当する。 The points to keep in mind regarding the technology explained in the examples will be described. The negative electrode bus bar 40 of the embodiment corresponds to an example of the first bus bar. Each of the flat plate 41, the negative electrode terminal hole 42, and the branch portion 43 of the negative electrode bus bar 40 corresponds to an example of the first flat plate, the first hole, and the first branch portion. The positive electrode bus bar 30 of the embodiment corresponds to an example of the second bus bar. Each of the flat plate 31, the positive electrode terminal hole 32, and the branch portion 33 of the positive electrode bus bar 30 corresponds to an example of the second flat plate, the second hole, and the second branch portion. The reinforcing rib 48 corresponds to an example of the first rib. The reinforcing rib 38 corresponds to an example of the second rib. The X direction of the coordinate system in the figure corresponds to the first direction, and the Y direction corresponds to the second direction.
　以上、本発明の具体例を詳細に説明したが、これらは例示に過ぎず、請求の範囲を限定するものではない。請求の範囲に記載の技術には、以上に例示した具体例を様々に変形、変更したものが含まれる。本明細書または図面に説明した技術要素は、単独であるいは各種の組合せによって技術的有用性を発揮するものであり、出願時請求項記載の組合せに限定されるものではない。また、本明細書または図面に例示した技術は複数目的を同時に達成し得るものであり、そのうちの一つの目的を達成すること自体で技術的有用性を持つものである。 Although specific examples of the present invention have been described in detail above, these are merely examples and do not limit the scope of claims. The techniques described in the claims include various modifications and modifications of the specific examples illustrated above. The technical elements described herein or in the drawings exhibit their technical usefulness alone or in various combinations, and are not limited to the combinations described in the claims at the time of filing. In addition, the techniques illustrated in the present specification or drawings can achieve a plurality of purposes at the same time, and achieving one of the purposes itself has technical usefulness.

Claims (6)

  1. 　電力変換用のスイッチング素子を収容しており、前記スイッチング素子と導通している第１端子と第２端子が側面から延びている複数のパワーモジュールが第１方向にて積層されている積層ユニットと、
    　前記積層ユニットの隣りに配置されているコンデンサと、
    　複数の前記パワーモジュールの前記第１端子と接合しているとともに、前記コンデンサの一方の電極と接続している第１バスバと、
    　複数の前記パワーモジュールの前記第２端子と接合しているとともに、前記コンデンサの他方の電極と接続している第２バスバと、
    を備えており、
    　複数の前記パワーモジュールの前記第１端子は、前記第１方向に沿って一列に並んでおり、複数の前記第２端子は、前記第１端子の列と平行に一列に並んでおり、
    　前記第１バスバは、前記コンデンサから前記パワーモジュールの前記側面に沿って延びている第１平板と、前記第１平板に設けられている複数の第１孔であってそれぞれに前記第１端子が通過している複数の第１孔と、それぞれの前記第１孔の縁から延びており、それぞれの前記第１端子と接続されている複数の第１枝部と、を備えており、
    　前記第２バスバは、前記コンデンサから前記第１平板と平行に延びている第２平板と、前記第２平板に設けられている複数の第２孔であってそれぞれに前記第２端子が通過している複数の第２孔と、それぞれの前記第２孔の縁から延びており、それぞれの前記第２端子と接続されている複数の第２枝部と、を備えており、
    　前記第１平板の前記コンデンサから遠い側の縁に第１リブが設けられている、電力変換器。     A laminated unit that houses a switching element for power conversion, and has a plurality of power modules in which a first terminal and a second terminal extending from the side surface are laminated in the first direction. ,
    The capacitors placed next to the laminated unit and
    A first bus bar that is joined to the first terminal of the plurality of power modules and is connected to one electrode of the capacitor.
    A second bus bar that is joined to the second terminal of the plurality of power modules and is connected to the other electrode of the capacitor.
    Is equipped with
    The first terminals of the plurality of power modules are arranged in a row along the first direction, and the plurality of second terminals are arranged in a row parallel to the row of the first terminals.
    The first bus bar is a first flat plate extending from the capacitor along the side surface of the power module, and a plurality of first holes provided in the first flat plate, each of which has a first terminal. It is provided with a plurality of first holes passing through and a plurality of first branch portions extending from the edge of each of the first holes and connected to each of the first terminals.
    The second bus bar is a second flat plate extending from the capacitor in parallel with the first flat plate, and a plurality of second holes provided in the second flat plate through which the second terminal passes. It is provided with a plurality of second holes, and a plurality of second branches extending from the edge of each of the second holes and connected to each of the second terminals.
    A power converter in which a first rib is provided on an edge of the first flat plate on the side far from the capacitor.
  2. 　前記第１方向に延びている前記第２平板の縁であって前記コンデンサから遠い側の縁に第２リブが設けられており、前記第１リブと前記第２リブは、互いに離間する方向に延びている、請求項１に記載の電力変換器。 A second rib is provided on the edge of the second flat plate extending in the first direction and far from the capacitor, and the first rib and the second rib are separated from each other. The power converter according to claim 1, which extends.
  3. 　前記第１平板と前記第１リブは一枚の金属板で作られている、請求項１または２に記載の電力変換器。 The power converter according to claim 1 or 2, wherein the first flat plate and the first rib are made of one metal plate.
  4. 　前記第１リブは前記第１平板に達する切欠を備えている、請求項１から３のいずれか１項に記載の電力変換器。 The power converter according to any one of claims 1 to 3, wherein the first rib has a notch that reaches the first flat plate.
  5. 　前記第１リブは複数の前記切欠を備えている、請求項４に記載の電力変換器。 The power converter according to claim 4, wherein the first rib includes a plurality of the notches.
  6. 　前記第１リブは、第１電力変換回路に用いられている第１の前記パワーモジュールと、第２電力変換回路に用いられている第２の前記パワーモジュールとの間に設けられている、請求項４または５に記載の電力変換器。 The first rib is provided between the first power module used in the first power conversion circuit and the second power module used in the second power conversion circuit. Item 4. The power converter according to Item 4.
PCT/JP2019/028536 2019-07-19 2019-07-19 Power converter WO2021014512A1 (en)

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Citations (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
JP2002190569A (en) * 2000-12-20 2002-07-05 Nissan Motor Co Ltd Semiconductor device
JP2015116056A (en) * 2013-12-12 2015-06-22 三菱自動車工業株式会社 Bus bar
JP2018042424A (en) * 2016-09-09 2018-03-15 トヨタ自動車株式会社 Power conversion device
JP2018042309A (en) * 2016-09-05 2018-03-15 トヨタ自動車株式会社 Power conversion device

Patent Citations (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
JP2002190569A (en) * 2000-12-20 2002-07-05 Nissan Motor Co Ltd Semiconductor device
JP2015116056A (en) * 2013-12-12 2015-06-22 三菱自動車工業株式会社 Bus bar
JP2018042309A (en) * 2016-09-05 2018-03-15 トヨタ自動車株式会社 Power conversion device
JP2018042424A (en) * 2016-09-09 2018-03-15 トヨタ自動車株式会社 Power conversion device

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